Carton 100mm f/13 "MD" OTA Construction - Etching Baffle Seats into Mylar Backed ProtoStar

 

Mylar backed ProtoStar etched to receive the baffle  rack. (Click to see an enlarged image)

 

After the Mylar backed ProtoStar flocking material was cut to size to perfectly fit the inside circumference of the main tube, the baffle rack was placed over it in its final position, as it would sit once it is slid into the main tube. The spacing and distance values were derived from the ray trace diagram. Then, using a small file with a sharp edge, a line was carefully etched across the flocking material creating a groove for each baffle sit in, so that once the flocking material is wrapped around the baffle rack, the grooves would aid in snugly holding each baffle in place without the baffle rack shifting.